System Architecture

The facility is controlled through a unified platform managing:

• 83 motors
• 647 valves
• 98 control loops
• 240 analog signals
• 11 automated mixers
• 50+ tanks

Recipes can be instantly transferred between mixers without reprogramming.

Testing & Reliability

The system was rigorously tested prior to commissioning:

• failure simulations (power, air, emergency stop)
• batch recovery without loss
• validation under real operating conditions

All scenarios were successfully handled, ensuring stable operation.

Operational Performance

• Continuous 24/7 operation
• High recipe repeatability
• Reduced operator workload
• Full traceability (SQL-based)
• Ready for future expansion

Control & Operation

A centralized HMI/SCADA system provides role-based access and features such as:

• real-time monitoring
• recipe management
• trends and alarms
• process simulation

Scalability

The modular architecture and standardized templates allow rapid integration of new equipment with minimal changes.

Conclusion

This project demonstrates the shift from machine control to full process automation.

RAP Systems delivered a reliable, scalable solution ready for autonomous production—an important step toward lights-out manufacturing.